MOULDING AND DEPOSITING


material C


hocolate moulds are a fundamental but often overlooked element of chocolate manufacturing. While shape and


design are highly visible, mould material also has an important role to play in surface finish, demoulding reliability, cooling performance, line efficiency and long-term cost of ownership. With confectionery manufacturers


facing increasing pressure around consistency, compliance and automation, mould selection is no longer a simple purchasing choice – it has become a strategic production decision. Mould materials include the following:


Plastic moulds: Food-grade plastic moulds made from PET, PVC or polystyrene are still used at the lowest end of production, particularly for seasonal items, demonstrations or test runs. Their low cost and availability make them accessible, but they do have significant limitations. They can scratch easily, deform under


heat, and degrade rapidly with repeated cleaning. Thermal performance is poor, resulting in longer cooling times, inconsistent crystallisation and reduced surface gloss. In practice, plastic moulds are generally considered to be single-use or short-life tools, and are unsuitable for repeat production.


Silicone moulds: Silicone moulds can offer flexibility and easy release, making them useful for prototypes, inclusions and highly complex decorative shapes. They are occasionally used in artisan settings, where form takes precedence over finish. However, the insulating nature of the


30 • KENNEDY’S CONFECTION • FEBRUARY 2026


SELECTING THE RIGHT CHOCOLATE MOULD


Mike Gee, Director at Premier Forrester, highlights the main mould materials in use today, and looks at the impact ofregulatory change.


material significantly slows cooling and limits gloss development. Dimensional stability is also an issue, particularly during filling and vibration, which makes silicone unsuitable for precision shell work or automated lines. As a result, silicone remains a niche solution, rarely used beyond development, decoration or specialist applications.


Polycarbonate moulds: Polycarbonate moulds remain the undisputed standard for professional chocolate production today. Their rigidity, thermal conductivity and ability to be polished to an ultra-fine finish enables superior gloss, sharp detail and consistent demoulding when tempering is correctly controlled. They are also compatible with vibration tables, cooling tunnels and modern depositing systems. Within this category, Hans Brunner is


recognised as a benchmark manufacturer. Its moulds are designed not just for appearance, but for repeatable industrial performance. This is particularly


critical in medium- and high-volume environments where downtime, rejects and inconsistency will directly impact profitability. In the UK and Ireland Premier Forrester acts as agent for Hans Brunner, providing local technical support and guidance


Bespoke moulds: Bespoke chocolate moulds are created using either injection moulding or thermoforming. Injection- moulded polycarbonate delivers high precision, surface quality and durability, which makes it well-suited to long-term production and branded lines applications. Thermoformed moulds offer a lower-cost route to custom shapes but with reduced detail definition and shorter lifespan.


Regulatory demands As material specifications evolve, tooling design becomes even more critical – particularly when adapting to new regulatory requirements. With effect from January 2025, the


THE RACE IS ON TO FIND NEW COMPLIANT MOULD MATERIALS… A PET-BASED COPOLYESTER APPEARS TO BE A PROMISING CANDIDATE.


EU banned the use of plastics containing Bisphenol A (BPA) in items that will come into contact with food and this affects almost all chocolate moulds used in industrial settings. An exemption was granted for chocolate moulds, with a transition period of 36 months. So, the race is now on to find new


compliant mould materials. According to Hans Brunner, a PET-based copolyester appears to be a promising candidate, but its effectiveness in industrial applications still needs to be evidenced and more than ever, as expectations around quality, efficiency and compliance rise, it is important that mould selection is aligned with long-term manufacturing strategy.


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